Proceedings of IOE Graduate Conference, 2017

Volume: 5 ISSN: 2350-8914 (Online), 2350-8906 (Print)

Design, Fabrication and Testing of Waste Plastic Pyrolysis Plant

Ajay Jayswal a , Arbind Kumar Sah b , Prabin Pradhananga c , Rohit Sah d , Hari Bahadur Darlami e
a, b, c, d, e
Department of Mechanical Engineering, Pulchowk Campus, Institute of Engineering, Tribhuvan University, Nepal
Corresponding Email: a ajayjayswal604@gmail.com, b arvindsah100@gmail.com, c 2prabinp2@gmail.com,
d sahrohit153@gmail.com, e haridarlami@gmail.com

Abstract
In recent decades, there has been a dramatic increment in plastic consumption. Used plastic is one of the major
wastes in many countries including Nepal. A lot of money is spent in land filling to process plastic wastes which
can pose a threat to environment in long run. The incineration of plastic wastes leads to severe air pollution.
Plastic pyrolysis process is a widely used technique to handle plastic wastes in many foreign countries. It is a new
technology in Nepalese context. It involves melting plastic wastes, vaporizing them, condensing the vapor and
distilling to obtain fuel. In the pyrolysis reactor, plastics are heated, vaporized and the vapor thus produced is
passed to shell and tube condenser for condensation. The liquid thus obtained is called pyrolysis oil and char
remains in pyrolysis reactor as residue. The yields depend on various factors like plastic type used, cracking
temperature of plastic, rate of heating, operation pressure of reactor, type of reactor, residence time, use of
catalyst, etc. The plant was designed and modeled in 3D CAD software, Solidworks. Batch reactor was employed
to pyrolyze Low Density Polyethylene at reactor base temperature of about 600°C and the vapour produced was
directed to horizontal, counter-flow shell and tube condenser. From 10 kg of plastics, the plant yielded 6.63 liters
of pyrolysis oil and 2.236 kg of char, on average, in the cost of 3.169 kg of LPG gas.
Keywords
Waste Plastic – Plastic Pyrolysis – Pyrolysis Oil – Shell and Tube Condenser

1. Introduction results in the formation of carbonized solid residue

Plastics are one of the most commonly used materials in
our daily life. They contribute to make our life
convenient. They are widely used in packaging and
manufacture of products including electronic,
automotive, etc [1]. Plastics have light weight and can
be simply formed. They can be reused and help to
conserve natural resources [2]. In fact, plastics have
been used to replace metals and wood. Resultantly,
plastic consumption has skyrocketed.
Plastic was invented in 1862 by Alexander Parkes [3].
They are formed by polymerization and have high
molecular mass. Other substances may be present in
plastics besides polymers to minimize costs and to
enhance performance [4]. Desired shape can be given to
these polymers by molding or by extrusion [5].
Plastic pyrolysis involves heating and degradation of
plastic polymers at temperatures between 350°C and
900°C in an oxygen deficient environment [2]. This
called char, condensible hydrocarbon oil and
non-condensible gas with high calorific value [2].
Scheirs et al. [5] stated that gases formed during the
pyrolysis of organic material include carbon monoxide,
carbon dioxide, water, hydrogen, methane, ethane,
ethene, propane, propene, butane, butene, etc. The
temperature and rate of heating can be controlled to
produce desired solid, liquid and gas products because
they have significant influence in pyrolysis process [5].
Yin et al. [6] have considered pyrolysis of waste plastic
as one of the outstanding methods of energy
regeneration. This is because waste plastic is an
important resource of chemicals, gas and liquid fuels
[6].
Mainly there are two types of plastics: thermoplastics
and thermosetting polymers. If enough heat is supplied,
thermoplastics can be softened and melted repeatedly.
On cooling, they are hardened, so that they can be used
to form new plastics products. Examples include

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Design, Fabrication and Testing of Waste Plastic Pyrolysis Plant

polyethylene, polystyrene, etc [4]. They are recyclable.
Thermosetting plastics can be melted and shaped only
once. It is not good to repeatedly heat treat such
plastics; therefore they remain in solid state after they
have been solidified [4]. Examples: epoxy resin, phenol
formaldehyde, etc [7]. Society of Plastics Industry (SPI)
has divided plastics into the following groups on the
basis of application and chemical structure.
• PET (Polyethylene Terephthalate)
• HDPE (High Density Polyethylene)
• PVC (Polyvinyl Chloride)
• LDPE (Low Density Polyethylene)
• PP (Polypropylene)
• PS (Polystyrene)
• Other
2. Design Procedure
2.1 Design of Pyrolysis Reactor
Determination of the amount of raw materials : 3. Fabrication and assembly
The experiment initially aimed towards performing
pyrolysis at large scale. For that, the volume occupied
by definite mass of plastics at normal market condition
was predicted. The volume appeared to be large. Hence,
it was chosen to preheat the plastics at low temperature
(below melting point) in reactor so that more plastics
could be accommodated in reactor. Finally, the volume
of reactor was predicted to process 10 kg of plastics.
to meet our requirements. Water boiling test was done
to determine stove efficiency. The plastic vapour
production rate was thus calculated and was used later
for the design of condenser.
2.2 Design of Condenser
Shell and tube condensers are employed for
condensation of process vapours and are mostly used in
the chemical process industries [8]. Shell and tube
condenser with very slight inclination to horizontal was
designed to be used in our experiment in order to
facilitate proper support and for the liquid oil to flow
naturally under the action of gravity for easy collection
in the flask. The detailed design procedure for
condenser has been given in table 4 in appendix.
All the 3D modeling and design of pyrolysis reactor,
condenser and overall plant were done in Solidworks
2016.
3.1 Fabrication of Pyrolysis Reactor

Determination of vessel geometry : The pyrolysis

reactor was designed to have the vertical cylindrical
cross section, called as shell. Heads, which are the
end caps of the reactor, were chosen to be kept flat to
lessen cost of fabrication, to ensure easy maintenance
and to allow for greater rate of heat transfer. The reactor
was designed to operate at normal atmospheric pressure.
Specific spots were located to attach pressure gauge, to
connect piping for guiding vapour to condenser and for Figure 1: Pyrolysis Reactor
the removal of char.

Analysis of heat required and selection of heating
system : The total amount of heat energy required to
heat, melt, boil, pyrolyze and vaporize 10 kg LDPE was
calculated. The heat transfer rate required and the LPG
fuel feed rate required were calculated. LPG stove was
selected based on its calorific value and stove efficiency
Scrap materials from the project done by Acharya et al.
[9] were extensively used for fabrication of reactor and
condenser. Locally available mild steel of thickness 3
mm was used for the fabrication of heads, shells and
conical cap. Fabrication processes of cutting and
welding were used [9]. Various specifications of

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pyrolysis reactor are listed in table 1. Table 2: Specifications of Condenser [9]

Specifications Value
Condenser type Shell and Tube
Table 1: Specifications of Pyrolysis Reactor [9]
Flow type Counter flow
Specifications Value Shell side Plastic Vapor
Outer Diameter 500 mm Copper tube side Water
Inner Diameter 494 mm Copper tube size Outer diameter = 12.7 mm
Height of reactor 476 mm Inner diameter = 10.92 mm
Capacity/Volume 91 liters (approx.) Tube length per pass 1.5 m
No. of passes 1
No. of copper tubes 12
No. of baffles 28
Two locally available cast iron water pipes of diameters Baffle Spacing 52 mm
1.5′′ and 2.5′′ were welded to the reactor, the former at
height of 396 mm and the latter, just above the base. Ball
valves were connected to each pipe [9]. The pressure 3.3 Assembly
gauge was installed in the former and the latter was used
The reactor and the condenser were connected via cast
as a pathway for char removal. A water pipe of 2.5′′
iron water tube of 2.5′′ diameter. A locally available
was also connected at the side of conical cap to allow
LPG stove was used as the heating source. Reactor was
plastic vapor to enter the condenser shell. Asbestos
placed on the stove and a simple furnace made of bricks
gasket and high temperature silicone were used to seal
and mud was constructed on it. The final assembly of
reactor and conical cap. Finally, nuts and bolts were
the plant is shown in figure 3.
used to connect them. Sensor of electronic temperature
measuring instrument was inserted inside the reactor via
feed hole.

3.2 Fabrication of Condenser

Figure 3: Waste Plastic Pyrolysis Plant

Figure 2: Condenser

4. Testing and Analysis

Condenser shell, baffles and cover plate were made from
mild steel [9]. The copper tubes were arranged in the
tube sheet and then brazed to form tube bundle. Gaskets
and high temperature silicone were used to seal cover
plate and shell of the condenser. Various specifications
of the condenser are enlisted in table 2.
Two water boiling tests were conducted to calculate the
efficiency of LPG stove. A known mass of water was
boiled in pyrolysis reactor by supplying LPG fuel of
known heating value. The ratio of theoretical heat
absorbed by water to boil plus pyrolysis reactor itself
and heat produced by burning total fuel actually

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Design, Fabrication and Testing of Waste Plastic Pyrolysis Plant

consumed to boil water gave the efficiency of stove. 4.2 Burning Test of Pyrolysis Oil
The average efficiency of stove was found to be 51.3%.
A simple burning test was performed as soon as a sample
Overall heat transfer coefficient of condenser was of pyrolysis oil was obtained. 50 ml of sample was taken
calculated using the data obtained from the experiment and simple tuki, as shown in figure 5, was made. It
which was 25.326 W /(m2 · K). The theoretical overall continued to burn for 1 hour and 16 minutes.
heat transfer coefficient calculated during design was
115.731 W /(m2 · K). This difference might have been
caused due to more fouling factors than expected,
variation in water flow rate than design value, rust
present in condenser, dissolved water in pyrolysis oil,
wastes in the plastics used, etc.
Three experiments of converting waste LDPE into fuel
were conducted. The plastics were obtained from a local
plastic scrap dealer. First test yielded 6.1 liters of oil and
2.488 kg of char in the expense of 3.096 kg of LPG fuel
in the total operation time of 5 hours and 28 minutes.
Similarly, second test yielded 7 liters of oil and 2.016 kg
char in 4 hours 44 minutes of the plant run. The third
test yielded 6.8 liters of oil and 2.2 kg char in 5 hours
10 minutes. The oil collected is shown in figure 4. The
actual performance of pyrolysis plant is given in table 5
Figure 4: Pyrolysis Oil
in appendix.
It was found that the heating rate has significant effect
in the oil production rate. Almost 900 ml of surplus
oil was collected in the second experiment than that of
the first one. Heating rate was drastically increased in
the second experiment. Moreover, it was also found
that without proper agitation mechanism, the plastics
are more prone to be charred. Thus, it is inevitable to
incorporate a proper agitator to ensure uniform heating
of all the plastics.

4.1 Properties of Pyrolysis Oil obtained

Two samples of pyrolysis oil were tested at the central
laboratory of Nepal Oil Corporation at Sinamangal,
Kathmandu. The test results are enlisted in table 3.

Table 3: Properties of Pyrolysis Oil

Figure 5: Tuki
Characteristics Test Sample 1 Sample 2
Method
Density ASTM 764.2 782.5 5. Conclusions
(@ 15°C, kg/m3 ) D1298
The following conclusions can be deduced from the
Kinematic Viscosity ASTM 0.992 1.507
project.
(@ 40°C, cSt) D445
• The existing technology and materials can be

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utilized to construct waste plastic pyrolysis plant
in Nepal.
• It is inevitable to incorporate a proper agitation
mechanism in the pyrolysis reactor to ensure
uniform heating of plastics. Otherwise, the
plastics present at bottom can get charred while
the plastics at above may remain unpyrolyzed.
• Appropriate heating rate has to be maintained in
order to obtain a good yield of pyrolysis oil. A
decreased heating rate does not give good yield of
oil.
• On average, 2.236 kg of char and 6.63 liters of
pyrolysis oil have been obtained from the
pyrolysis of 10 Kg of waste LDPE in the cost of
3.169 kg of LPG gas.
6. Recommendations
• Further research on possibility of pyrolysis of
other types of plastic like PET, HDPE, etc using
locally available technology and materials can be
done.
• Stainless steel should be used in place of mild
steel in order to avoid rusting and for higher heat
conductivity.
• Recirculation of excess gas to the furnace region
can be done in order to conserve the fuel. Excess
gases are the gases which the condenser is unable
to condense but they are still flammable. Hence,
they can be utilized as heating source.
• CFD simulation can be done for more accurate
analysis.
• Use of stirring mechanism in pyrolysis reactor can
increase the yield of pyrolysis oil.
• The properties of plastic pyrolysis oil like density,
viscosity, etc can be improved by blending the
oil with diesel. Hence, further study about diesel
blended plastic pyrolysis oil can be done.
Acknowledgments
The authors are grateful to Dr. Iswor Bajracharya
(Technical Officer, Bioenergy Laboratory, NAST), Dr.
Rabindra Prasad Dhakal (Senior Scientist, Faculty of
Technology, NAST) and Er. Ankita Shrestha (NAST)
for granting access to the plastic pyrolysis plant there at
NAST. Thanks to Dr. Ajay Kumar Jha (Assistant
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Proceedings of IOE Graduate Conference, 2017
Professor, IOE, Pulchowk Campus) and Er. Shailendra
Bhusal (Nepal Oil Corporation) for their immense help
during the project.
References
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[6] L.J. Yin, D.Z. Chen, H. Wang, X.B. Ma, and G. M.
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plastics pyrolysis. Chemical Engineering Journal,
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[7] UNEP. Converting Waste Plastics into a Resource:
Compendium of Technologies. 2009.
[8] Robert W. Serth. Process Heat Transfer Principles and
Applications. Academic Press, 2007.
[9] Krishna P. Acharya, Manoj Poudel, Rinoj Gautam,
Sharad R. Acharya, and Hari B. Darlami. Design,
Fabrication and Performance Testing of Pine Resin
Processing Plant. Department of Mechanical
Engineering, IOE, Pulchowk Campus, 2012.
[10] Eugene F. Megyesy. Pressure Vessel Handbook.
Pressure Vessel Publishing, Inc., 2001.
[11] Dennis R. Moss and Michael Basic. Pressure Vessel
Design Manual. Butterworth-Heinemann, 4th edition,
2013.
[12] Andrew J. Peacock. Handbook of Polyethylene
Structures, Properties, and Applications. Marcel
Dekker, Inc, 2000.
[13] Feng Gao. A thesis Submitted in fulfilment of the
requirements for the Degree of Doctor of Philosophy in
Chemical and Process Engineering. 2010.
[14] Frank P. Incropera, David P. DeWitt, Theodore L.
Bergman, and Adrienne S. Lavine. Fundamentals of
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[15] R.K. Rajput. Heat and Mass Transfer. S. Chand, 2001.
Design, Fabrication and Testing of Waste Plastic Pyrolysis Plant

Appendix

Table 4: Analysis of Design

Inputs Calculations Outputs
Design of Reactor
Internal Design Pressure, t = 0.522 mm.
P = 103425 N/m 2 Considering the
Internal Radius, r = 0.247 m safety factor, the
P×r
Allowable Stress, S = Thickness of Reactor Shell, t = S×E−0.6×P [11] calculated thickness of
70 MPa @ 850°F [10] reactor shell has been
Weld Joint Efficiency, E = 70 % increased to 3 mm.
for butt joints [10] Hence, t = 3 mm
Design of Condenser [8, 9]
Heating value of LPG per kg,
Heat taken by 10 kg solid plastics till it starts melting
QHv = 46100 kJ/kg
at 110°C, Q1 = m ×Cp × ∆T = 1785 kJ
Specific heat capacity of LDPE,
Heat required to completely melt 10 kg plastics at
Cp = 2100 J/(kg · K)
110°C, Q2 = m × L f = 1213.65 kJ
Specific heat capacity of water,
Heat taken by 10 kg liquid plastics till it reaches
Cw = 4187 J/(kg · K)
450°C, Q3 = m ×Cp × ∆T = 7140 kJ
Average value of heat of fusion
Heat required for pyrolysis, Q4 = 10 × 1047.62 =
of LDPE, L f = 29 cal/g [12]
10476.2 kJ
Heat required for pyrolysis plus
Total heat required, Q = 20614.85 kJ
vaporization of 1 kg liquid PE
Take 21000 kJ
= 1047.62 kJ [13]
Heat transfer rate required = TotalTime heat required
taken =
LPG Stove Efficiency = 51.3 %
7000 kJ/hr
Latent heat of vaporization of
Plastic vapor production rate =
LDPE = 180.46 kJ/kg [13] Heat transfer rate Condenser is designed
Latent heat of vaporization = 38.7898 kg/hr
Assumed time for complete for vapor flow rate of
Mass flow rate of oil vapor, ṁo = 38.7898 kg/hr =
pyrolysis = 3 hr 38.7898 kg/hr
10.775 × 10−3 kg/s
Do = 12.7 mm, Di =
Heat load in condenser, q = (ṁoCp ∆t)oil =
10.92 mm, L = 1.5 m, ktube =
10.775 × 10−3 × 2100 × (450 − 50) = 9050.953 J/s
400 W /(m · K)
For safe design, q = 10 kJ/s
Viscosity of water,
Mass flow rate of water, ṁw = Cw (Twoq−Twi ) =
µw = 855 × 10−6 (N · s)/m2
429.902 kg/hr
Thermal conductivity of water,
Calculation of Logarithmic Mean Temperature
kw = 0.613 W /(m · K)
Difference (LMTD) [8]
Assumed temperatures:
∆T1 = Toi − Two = 405°C
Ambient temperature, Ta = 25°C
∆T2 = Too − Twi = 25°C
Vapor inlet, Toi = 450°C ∆T2 −∆T1
LMT D = ln(∆T = 136.445°C
Oil outlet, Too = 50°C 2 /∆T1 )
Correction Factor, F = 0.882
Water inlet, Twi = 25°C
Corrected LMTD, ∆Tm = F × LMT D = 120.344°C
Water outlet, Two = 45°C

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Design overall heat transfer coefficient, UD =

269.717 W /(m2 · K) [8]
q
Heat transfer area, A = UD ×∆T m
= 0.308 m2
0.308
Number of tubes, nt = π ×DA0 ×L = π ×12.7×10 −3 ×1.5 =
5.146
Choose nt = 8 and check if UD ≥ Ureq
A = nt (π × D0 × L) = 8 × (π × 12.7 × 10−3 × 1.5) =
0.479 m2
q
Ureq = A×∆T m
= 173.476 W /(m2 · K)
Determine UD using Nusselt’s Theory [8]
Mass flow rate through each tube = ṁ pertube =
0.015 kg/s
4ṁ
Reynolds number = π ×Dpertube i × µw
[8]
Re = 2045.562, Re < 2300, flow is laminar
Nu = 3.66 [14], Nu = hi k×D w
i

Convective heat transfer coefficient inside tube, hi =

205.456 W /(m2 · K) Number of copper
Condensing-side heat transfer coefficient, h0 = tubes to be used in
k3 ρ 2 g
1.52[ 4l µllτ ]1/3 where τ = L(nṁ)o2/3 [8] condenser = 12
t
τ = 1.796 × 10−3 kg/(m · s)
h0 = 3887.425 W /(m2 · K)
Clean overall coefficient,
D0 ln( Do )
UC = [ hDi D0 i + 2ktubeDi + h10 ]−1 [15]
UC = 168.92 W /(m2 · K)
RD0 = 0.0009 (m2 · °C)/W [15]
RDi = 0.0004 (m2 · °C)/W [15]
R D
Total fouling allowance, RD = DDi i 0 + RD0 =
0.00137 (m2 · °C)/W
Design overall coefficient, UD = ( U1C + RD )−1
UD = 137.175 W /(m2 · K)
UD < Ureq
Similarly, 2nd iteration: nt = 10, UD < Ureq
Similarly, 3rd iteration: nt = 12, UD > Ureq
Condenser is thermally suitable for nt = 12

Table 5: Actual Performance of Pyrolysis Plant

Particulars Test 1 Test 2 Test 3
Mass of plastics used (kg) 10 10 10
Total oil production 6.1 liters (4.697 kg) 7 liters (5.39 kg) 6.8 liters (5.236 kg)
Total char production (kg) 2.488 2.016 2.2
Total water obtained (liters) 0.880 0.850 0.550
Fuel consumption LPG (kg) 3.096 3.286 3.125
Estimated amount of gas formed (kg) 1.935 1.744 2.014
Time of operation 5 hrs 28 mins 4 hrs 44 mins 5 hrs 10 mins

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Design, Fabrication and Testing of Waste Plastic Pyrolysis Plant

Figure 6: 3D Model of Waste Plastic Pyrolysis Plant

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